4TNE98 Engine Service Manual
4TNE98 Engine Service Manual
Jan. 2008
Service Manual
4TNV98 & 4TNE98 Diesel Engine
Most accidents involving product operation, maintenance and repair are caused by failure to observe basic
safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations
before an accident occurs. A person must be alert to potential hazards. This person should also have the
necessary training, skills and tools to perform these functions properly.
Read and understand all safety precautions and warnings before operating or performing lubrication,
maintenance and repair on this product.
Basic safety precautions are listed in the Safety section of the Service or Technical Manual. Additional safety
precautions are listed in the Safety section of the owner/operation/maintenance publication.
Specific safety warnings for all these publications are provided in the description of operations where hazards
exist. WARNING labels have also been put on the product to provide instructions and to identify specific
hazards. If these hazard warnings are not heeded, bodily injury or death could occur to you or other persons.
Warnings in this publication and on the product labels are identified by the following symbol.
WARNING
Improper operation, lubrication, maintenance or repair of this product can be dangerous and could
result in injury or death.
Do not operate or perform any lubrication, maintenance or repair on this product, until you have read
and understood the operation, lubrication, maintenance and repair information.
Operations that may cause product damage are identified by NOTICE labels on the product and in this
publication.
DOOSAN cannot anticipate every possible circumstance that might involve a potential hazard. The warnings
in this publication and on the product are therefore not all inclusive. If a tool, procedure, work method or
operating technique not specifically recommended by DOOSAN is used, you must satisfy yourself that it is
safe for you and others. You should also ensure that the product will not be damaged or made unsafe by the
operation, lubrication, maintenance or repair procedures you choose.
The information, specifications, and illustrations in this publication are on the basis of information available at the
time it was written. The specifications, torques, pressures, measurements, adjustments, illustrations, and other
items can change at any time. These changes can affect the service given to the product. Obtain the complete and
most current information before starting any job. DOOSAN dealers have the most current information available.
Section 8. TROUBLESHOOTING
4TNE98 ENGINE
Figure 4-1b
4TNE98 ENGINE
Figure 4-2
(97/68/EC)
Components Functions
The starter motor is powered by the battery. When you turn the key
switch in the operators console to the START position, the starter motor
Starter Motor engages with the ring gear installed on the flywheel and starts the
flywheel in motion.
Components Functions
The TNV engine is liquid-cooled by means of a cooling system. The
cooling system consists of a radiator, radiator cap, engine cooling
fan, engine coolant pump,thermostat, and reserve tank. Note that
Cooling System all cooling system components are required for proper engine
operation. Since some of the components are application
specific, they must be carefully selected by an application
engineer. The application specific items are not part of the
basic engine package as shipped from the Yanmar factory.
The engine cooling fan is driven by a V-belt which is powered by the
Engine Cooling Fan
crankshaft V-pulley. The purpose of the engine cooling fan is to
circulate air through the radiator.
The engine coolant pump circulates the engine coolant through the
Engine Coolant Pump
cylinder block and the cylinder head and returns the engine coolant
to the radiator.
The radiator acts as a heat exchanger. As the engine coolant
Radiator circulates through the cylinder block it absorbs heat. The heat in the
engine coolant is dissipated in the radiator. As the engine cooling fan
circulates air through the radiator, the heat is transferred to the air.
The radiator cap controls the cooling system pressure. The cooling
system is pressurized to raise the boiling point of the engine coolant.
As the engine coolant temperature rises, the system pressure and
the coolant volume increases. When the pressure reaches a preset
Radiator Cap value, the release valve in the radiator cap opens and the excess
engine coolant flows into the reserve tank. As the engine coolant
temperature is reduced, the system pressure and volume is reduced
and the vacuum valve in the radiator cap opens allowing the engine
coolant to flow from the reserve tank back into the radiator.
The reserve tank contains the overflow of engine coolant from the
Reserve Tank radiator. If you need to add engine coolant to the system, add it to
the reserve tank; not the radiator.
A thermostat is placed in the cooling system to prevent the engine
coolant from circulating into the radiator until the engine coolant
temperature reaches a preset temperature. When the engine is cold,
no engine coolant flows through the radiator. Once the engine
Thermostat
reaches its operating temperature, the thermostat opens and allows
the engine coolant to flow through the radiator. By letting the engine
warm up as quickly as possible, the thermostat reduces engine
wear, deposits and emissions.
Diesel Fuel Specifications The PAH (polycyclic aromatic hydrocarbons) content should
be below 10% by volume.
Diesel fuel should comply with the following
specifications. The table lists several worldwide The metal content of Na, Mg, Si, and Al should be equal to or
specifications for diesel fuels. lower than 1 mass ppm. (Test analysis method JPI-5S-44-95)
.
Diesel Fuel Location Lubricity: The wear mark of WS1.4 should be Max. 0.018 in
Specification (460 m) at HFRR test.
No. 2-D, No. 1-D, USA
ASTM D975-94 Bio-Diesel Fuels
European
EN590:96 In Europe and in the United States, as well as some
Union
other countries, non-mineral oil based fuel
ISO 8217 DMX International resources such as RME (Rapeseed Methyl Ester)
United and SOME (Soybean Methyl Ester), collectively
BS 2869-A1 or A2 known as FAME (Fatty Acid Methyl Esters), are
Kingdom
JIS K2204 Grade No. being used as extenders for mineral oil derived
Japan diesel fuels.
2
KSM-2610 Korea Yanmar approves the use of bio-diesel fuels that do
not exceed a blend of 5% (by volume) of FAME with
GB252 China 95% (by volume) of approved mineral oil derived
diesel fuel. Such bio-diesel fuels are known in the
marketplace as B5 diesel fuels.
Additional Technical Fuel Requirements
These B5 diesel fuels must meet certain
The fuel cetane number should be equal to 45 or higher.
requirements.
The sulfur content must not exceed 0.5% by volume. Less
1. The bio-fuels must meet the minimum
than 0.05% is preferred.
specifications for the country in which they
areused.
Bio-Diesel fuels. See Bio-Diesel Fuels on page 4-9.
In Europe, bio-diesel fuels must comply with the European
NEVER mix kerosene, used engine oil, or residual fuels with
Standard EN14214.
the diesel fuel.
In the United States, bio-diesel fuels must comply with the
The water and sediment in the fuel should not exceed 0.05%
American Standard ASTM D-6751.
by volume.
2. Bio-fuels should be purchased only from
Keep the fuel tank and fuel-handling equipment clean at all
recognized and authorized diesel fuel suppliers.
times.
CAUTION
Only use diesel fuels recommended by Yanmar
for the best engine performance, to prevent
engine
damage and to comply with EPA / ARB warranty
requirements.
Only use clean diesel fuel.
NEVER remove the primary strainer (if equipped)
from the fuel tank filler port. If removed, dirt and
debris could get into the fuel system causing it
to clog.
1. Place an approved container under the air bleed 6. NEVER use the starter motor to crank the engine
port. in order to prime the fuel system. This may cause
the starter motor to overheat and damage the
2. Loosen the air bleed port 2 or 3 turns. coils, pinion and/or ring gear.
Figure 4-4
Use an engine oil that meets or exceeds the Engine Oil Viscosity
following guidelines and classifications:
Select the appropriate engine oil viscosity based on
Service Categories the ambient temperature and use the SAE Service
Grade Viscosity Chart in Figure 4-4a.
API Service Categories CD or higher
Definitions
1. Make sure the engine is level. 1. Make sure the engine is level.
2. Remove the dipstick (Figure 4-5, (1)) and wipe it 2. Remove the oil cap (Figure 4-5, (4)).
with clean cloth.
3. Add the indicated amount of engine oil at the top
3. Fully reinsert the dipstick. or the side engine oil filler port (Figure 4-5, (5)).
4. Remove the dipstick. The oil level should be 4. Wait three minutes and check the oil level.
between the upper (Figure 4-5, (2)) and lower
(Figure 4-5, (3)) lines on the dipstick. 5. Add more oil if necessary.
5. Fully reinsert the dipstick. 6. Reinstall the oil cap (Figure 4-5, (4)) and hand-
tighten. Over-tightening may damage the cap.
Dipstick Upper
Engine Model
Limit / Lower Limit
11.1 / 6.3 qt
4TNV98
(10.5 / 6.0 L)
9.7 / 7.6 qt
4TNE98
(9.2 / 7.2 L)
Figure 4-5
DANGER CAUTION
Use a Long Life Coolant (LLC) or an Extended Life Fill the radiator and reserve tank as follows. This
Coolant (ELC) that meets or exceeds the following procedure is for filling the radiator for the first time
guidelines and specifications: or refilling it after it is flushed. Note that a typical
radiator is illustrated (Figure 4-6).
Additional Technical Coolant
Specifications:
Notes:
Figure 4-7
Engine Coolant
Engine Model
Capacity
Figure 4-8
3. Pour the engine coolant slowly into the radiator Description of Model Number
until it is even with the lip of the engine coolant
filler port. Make sure that air bubbles do not
develop as you fill the radiator.
1 PS = 0.7355 kW
*** Engine oil capacity for a Deep Standard oil pan. Refer to the operation manual provided by the driven
machine manufacturer for the actual engine oil capacity of your machine.
CAUTION
The tightening torque in the Standard Torque
Chart (see General Service Information section)
should be applied only to the bolts with a 7
head. (JIS strength classification: 7T)
Apply 60% torque to bolts
that are not listed.
Apply 80% torque when
tightened to aluminum alloy.
Nominal Thread
Item Tightening Torque Remarks
Diameter x Pitch
9 - 12 ftlb
(112 - 148 in.lb,
M8
12.7 - 16.7 Nm,
1.3 - 1.7 kgfm)
14 - 19 ftlb
(173 - 225 in.lb,
M10
19.6 - 18.734 Nm,
2.0 - 3.5 kgfm)
Pipe Joint Bolt 18 - 25 ftlb .
M12 (24.5 - 34.3 Nm,
2.5 - 3.5 kgfm)
29 - 36 ftlb
M14 (39.2 - 49.0 Nm,
4.0 5.0 kgfm)
36 - 43 ftlb
M16 (49.0 - 58.8 Nm,
5.0 - 6.0 kgfm)
NOTE: Torque values shown in this manual are for clean, non-lubricated fasteners unless otherwise specified.
micro
% percent
F = (1.8 x C) + 32
C = 0.556 x (F - 32)
DANGER DANGER
EXPLOSION HAZARD!
NEVER check the remaining battery charge by SCALD HAZARD!
shorting out the terminals. This will result in a NEVER remove the radiator cap if the engine is
spark and may cause an explosion or fire. Use a hot. Steam and hot engine coolant will spurt out
hydrometer to check the remaining battery and seriously burn you. Allow the engine to
charge. cool down before you attempt to remove the
If the electrolyte is frozen, slowly warm the radiator cap.
battery before you recharge it. Tighten the radiator cap securely after you
Failure to comply will result in death or serious check the radiator. Steam can spurt out during
injury. engine operation if the cap is loose.
ALWAYS check the level of the engine coolant
by observing the reserve tank.
Failure to comply will result in death or serious
injury.
DANGER
DANGER
FIRE AND EXPLOSION HAZARD!
Only use the key switch to start the engine.
NEVER jump-start the engine. Sparks caused by
shorting the battery to the starter terminals may
cause a fire or explosion. FIRE AND EXPLOSION HAZARD!
Failure to comply will result in death or serious Diesel fuel is flammable and explosive under
injury. certain conditions.
Only fill the fuel tank with diesel fuel. Filling the
fuel tank with gasoline may result in a fire and
will damage the engine.
NEVER refuel with the engine running.
Wipe up all spills immediately.
Keep sparks, open flames or any other form of
ignition (match, cigarette, static electric source)
well away when refueling.
NEVER overfill the fuel tank.
Fill the fuel tank. Store any containers
containing fuel in a well-ventilated area, away
from any combustibles or sources of ignition.
Failure to comply will result in death or serious
injury.
DANGER
DANGER
Failure to comply could result in death or Before you start the engine make sure that all
serious injury. bystanders are clear of the area.
Keep children and pets away while the engine is
operating.
Check before starting the engine that any tools
or shop rags used during maintenance have
been removed from the area.
Failure to comply could result in death or
serious injury.
BURN HAZARD!
Keep your hands and other body parts away
from hot engine surfaces such as the muffler,
exhaust pipe, turbocharger (if equipped) and
engine block during operation and shortly after
you shut the engine down. These surfaces are
extremely hot while the engine is operating and
could seriously burn you.
Failure to comply could result in death or
serious injury.
BURN HAZARD!
Batteries contain sulfuric acid. NEVER allow
EXPOSURE HAZARD! battery fluid to come in contact with clothing,
skin or eyes. Severe burns could result.
Wear personal protective equipment such as ALWAYS wear safety goggles and protective
gloves, work shoes, eye and hearing protection clothing when servicing the battery. If battery
as required by the task at hand. fluid contacts the eyes and / or skin,
NEVER wear jewelry, unbuttoned cuffs, ties or immediately flush the affected area with a large
loose-fitting clothing when you are working amount of clean water and obtain prompt
near moving/rotating parts such as the cooling medical treatment.
fan, flywheel or PTO shaft. Failure to comply could result in death or
ALWAYS tie back long hair when you are serious injury.
working near moving/rotating parts such as a
cooling fan, flywheel, or PTO shaft.
NEVER operate the engine while wearing a
headset to listen to music or radio because it
will be difficult to hear the alert signals. WARNING
Failure to comply could result in death or
serious injury.
HIGH-PRESSURE HAZARD!
Avoid skin contact with the high-pressure
diesel fuel spray caused by a fuel system leak
such as a broken fuel injection line. High-
pressure fuel can penetrate your skin and result
in serious injury. If you are exposed to high-
pressure fuel spray, obtain prompt medical
treatment.
NEVER check for a fuel leak with your hands.
ALWAYS use a piece of wood or cardboard.
Have your authorized Yanmar industrial engine
dealer or distributor repair the damage.
Failure to comply could result in death or
serious injury.
BURN HAZARD!
SHOCK HAZARD! If you must drain the engine oil while it is still
Turn off the battery switch (if equipped) or hot, stay clear of the hot engine oil to avoid
disconnect the negative battery cable before being burned.
servicing the electrical system. ALWAYS wear eye protection.
Check the electrical harnesses for cracks, Failure to comply could result in death or
abrasions, and damaged or corroded serious injury.
connectors. ALWAYS keep the connectors and
terminals clean.
Failure to comply could result in death or
serious injury.
WARNING
WARNING
BURN HAZARD!
Wait until the engine cools before you drain the
engine coolant. Hot engine coolant may splash
and burn you.
ENTANGLEMENT HAZARD! Failure to comply could result in death or
Stop the engine before you begin to service it. serious injury.
NEVER leave the key in the key switch when
you are servicing the engine. Someone may
accidentally start the engine and not realize you
are servicing it. This could result in a serious
injury.
If you must service the engine while it is
operating, remove all jewelry, tie back long hair,
and keep your hands, other body parts and
clothing away from moving/rotating parts.
Failure to comply could result in death or
serious injury.
CAUTION
CAUTION
Only use the engine coolant specified. Other
engine coolants may affect warranty coverage,
cause an internal buildup of rust and scale
and/or shorten engine life.
Prevent dirt and debris from contaminating the
FLYING OBJECT HAZARD! engine coolant. Carefully clean the radiator cap
ALWAYS wear eye protection when servicing and the surrounding area before you remove
the engine and when using compressed air or the cap.
high-pressure water. Dust, flying debris, NEVER mix different types of engine coolants.
compressed air, pressurized water or steam This may adversely affect the properties of the
may injure your eyes. engine coolant.
Failure to comply may result in minor or
moderate injury.
CAUTION
NEVER attempt to modify the engines design
CAUTION or safety features such as defeating the engine
Only use diesel fuels recommended by Yanmar speed limit control or the diesel fuel injection
for the best engine performance, to prevent quantity control.
engine damage and to comply with EPA/ARB Modifications may impair the engines safety
warranty requirements. and performance characteristics and shorten
Only use clean diesel fuel. the engines life. Any alterations to this engine
may void its warranty. Be sure to use Yanmar
NEVER remove the primary strainer (if genuine replacement parts.
equipped) from the fuel tank filler port. If
removed, dirt and debris could get into the fuel
system causing it to clog.
CAUTION
Observe the following environmental operating
conditions to maintain engine performance and CAUTION
avoid premature engine wear:
Make sure the engine is installed on a level
The standard range of ambient temperatures surface. If a continuously running engine is
for the normal operation of Yanmar engines is installed at an angle greater than (IDI = 25, DI =
from +5F (-15C) to +113F (+45C). 30) in any direction or if an engine runs for
If the ambient temperature exceeds +113F short periods of time (less than three minutes)
(+45C) the engine may overheat and cause at an angle greater than (IDI = 30, DI = 35) in
the engine oil to break down. any direction, engine oil may enter the
If the ambient temperature is below +5F (- combustion chamber causing excessive engine
15C) the engine will be hard to start and the speed and white exhaust smoke. This may
engine oil may not flow easily. cause serious engine damage.
Contact your authorized Yanmar industrial
engine dealer or distributor if the engine will
be operated outside of this standard
temperature range.
CAUTION
NEVER hold the key in the START position for
longer than 15 seconds or the starter motor will
overheat.
CAUTION
CAUTION
CAUTION
NEVER overfill the engine with engine oil.
It is important to perform daily checks. ALWAYS keep the oil level between the upper
Periodic maintenance prevents unexpected and lower lines on the oil cap/dipstick.
downtime, reduces the number of accidents due
to poor machine performance and helps extend
the life of the engine.
This section of the Service Manual describes the Yanmar recommends that you use genuine Yanmar
procedures for proper care and maintenance of the parts when replacement parts are needed. Genuine
engine. replacement parts help ensure long engine life.
Engine deterioration and wear occurs in proportion To maintain optimum engine performance and
to length of time the engine has been in service and compliance with the Environmental Protection
the conditions the engine is subject to during Agency (EPA) Regulations Non-road Engines and
operation. Periodic maintenance prevents the California Air Resources Board (ARB,
unexpected downtime, reduces the number of California), it is essential that you follow the
accidents due to poor machine performance and Periodic Maintenance Schedule on page 41 and
helps extend the life of the engine. Periodic Maintenance Procedures on page 43.
CAUTION
Establish a periodic maintenance plan
according to the engine application and make
sure you perform the required periodic
maintenance at the intervals indicated. Failure
to follow these guidelines will impair the
engines safety and performance characteristics,
shorten the engines life and may affect the
warranty coverage on your engine.
See Yanmar Limited Warranty in Warranty
Section.
Consult your authorized Yanmar dealer or
distributor for assistance when checking items
marked with a.
NOTE: These procedures are considered normal maintenance and are performed at the owners expense.
Daily WARNING
Follow these procedures for hazardous waste 4. Be sure to prime the diesel fuel system when you
disposal. Failure to follow these procedures may are done. See Priming the Fuel System on
seriously harm the environment. page15.
Follow the guidelines of the EPA or other
governmental agency for the proper disposal of Check Fuel Hoses and Engine Coolant
hazardous materials such as engine oil, diesel Hoses
fuel and engine coolant. Consult the local
authorities or reclamation facility. Daily check the fuel system and engine coolant
system hoses. If they are cracked or degraded,
NEVER dispose of hazardous materials replace them.
irresponsibly by dumping them into a sewer, on
the ground or into ground water or waterways.
0000013en.
Figure 5-1
NOTE: The oil drain plug may be in another 8. Dispose of used oil properly.
location if an optional oil pan is used.
Remove the engine oil filter as follows:
Drain the engine oil as follows:
1. Turn the engine oil filter (Figure 5-2, (2))
1. Make sure the engine is level. counterclockwise (Figure 5-2, (3)) using a filter
wrench.
2. Start the engine and bring it up to operating
temperature.
Figure 5-2
4TNV98 A408065
4TNE98 A408065
Figure 5-1
5. Warm up the engine by running it for five minutes 1. Press the V-belt down with your thumb with a
and check for any engine oil leaks. force of approximately 22 ftlb (98 Nm; 10 kgf) to
check the deflection.
6. After engine is warm, shut it off and let it sit for 10 There are three positions to check for V-belt
minutes. tension (Figure 5-4, (A), (B) and (C)). You can
check the tension at whichever position is the
7. Recheck the engine oil level. most accessible. The proper deflection of a used
V-belt at each position is:
8. Add engine oil (Figure 5-3, (5)) as needed until
the level is between the upper (Figure 5-3, (2)) Used V-Belt Tension
and lower lines (Figure 5-3, (3)) shown on the
dipstick (Figure 5-3, (1)). A B C
3/8 - 1/2 in. 1/4 - 3/8 in. 5/16 - 1/2 in.
(10 - 14 mm) (7 - 10 mm) (9 - 13 mm)
Figure 5-4
Figure 5-3
A B C
3/8 - 1/2 in. 1/4 - 3/8 in. 5/16 - 1/2 in.
(10 - 14 mm) (7 - 10 mm) (9 - 13 mm)
A B C
5/16 - 7/16 in. 3/16 - 5/16 in. 1/4 - 7/16 in.
(8 - 12 mm) (5 - 8 mm) (7 - 11 mm)
CAUTION
Figure 5-7
DANGER
Figure 5-8
FIRE AND EXPLOSION HAZARD! 2. Remove the fuel cap (Figure 5-9, (3)).
Diesel fuel is flammable and explosive under 3. Remove the drain plug (Figure 5-9, (2)) of the
certain conditions. fuel tank to drain the contaminates (water, dirt,
When you remove any fuel system component etc.) from the bottom of the tank.
to perform maintenance (such as changing the
fuel filter) place an approved container under
the opening to catch the fuel.
NEVER use a shop rag to catch the fuel. Vapors
from the rag are flammable and explosive.
Wipe up any spills immediately.
Wear eye protection. The fuel system is under
pressure and fuel could spray out when you
remove any fuel system component.
Failure to comply will result in death or serious
injury.
Figure 5-9
CAUTION
Note that a typical radiator is shown in Figure 5-10 The governor lever and engine speed control
for illustrative purposes only. (throttle lever, pedal, etc.) of the machine are
connected together by a throttle cable or rod. If the
Blow off dirt and dust from fins and radiator with cable becomes stretched, or the connections
28 psi (0.19 MPa; 2 kgf/cm) or less of loosen, the governor lever may not respond to
compressed air (Figure 5-10, (1)). Be careful not change of engine speed control position. This may
to damage the fins with the compressed air. make operation of the machine unsafe. Check the
If there is a large amount of contamination on the cable periodically and adjust if necessary.
fins, apply detergent, thoroughly clean and rinse
with tap water. NEVER force the throttle cable or pedal to move.
This may deform the governor lever or stretch the
cable and cause irregular operation of the engine
CAUTION speed control.
NEVER use high-pressure water or compressed
air at greater than 28 psi (193 kPa; 19 686
mmAq) or a wire brush to clean the radiator fins.
Radiator fins damage easily.
4TNV98 ENGINE
Clean Air Cleaner Element
4TNE98 ENGINE
Figure 5-12
CAUTION
Figure 5-11
CAUTION
Only use the engine oil specified. Other engine
oils may affect warranty coverage, cause
internal engine components to seize and / or
shorten engine life.
Prevent dirt and debris from contaminating the
engine oil. Carefully clean the oil cap/dipstick
and the surrounding area before you remove
the cap.
NEVER mix different types of engine oil. This
Figure 5-13 may adversely affect the lubricating properties
of the engine oil.
5. The inner element should not be removed when
NEVER overfill. Overfilling may result in white
cleaning or replacing the outer element. The
exhaust smoke, engine overspeed or internal
inner element is used to prevent dust from
damage.
entering the engine while servicing the outer
element.
Applicable Fuel Filter Part No. 8. Check the condition of the drain plug O-ring
(Figure 5-15a, (4)). Replace the O-ring if
4TNV98 A408064 damaged.
Figure 5-15
12. Dispose of the fuel, fuel filters and O-ring (if FIRE AND EXPLOSION HAZARD!
replaced) properly. Follow the guidelines of the
Diesel fuel is flammable and explosive under
EPA or other government agency.
certain conditions.
13. Carefully install the output nipple (Figure 5-15, NEVER use diesel fuel as a cleaning agent.
(8)). Failure to comply will result in death or serious
injury.
14. Carefully install the fuel filter sensor assembly
(Figure 5-15, (5)) in the new fuel filter using the
new O-ring supplied with the fuel filter (Figure
5-15, (2)) by turning the fuel filter sensor
assembly to the right (Figure 5-15, (9)). DANGER
15. Install the drain plug (Figure 5-15, (1)) on the
new fuel filter (Figure 5-15, (3)) by turning the
drain plug to the right (Figure 5-15, (8)). Hand
tighten only.
FIRE AND EXPLOSION HAZARD!
16. Clean the fuel filter mounting surface (Figure 5- Diesel fuel is flammable and explosive under
15, (10)) and apply a small amount of diesel fuel certain conditions.
to the gasket of the new filter.
When you remove any fuel system component
17. Install the new fuel filter (Figure 5-14, (2)) by to perform maintenance (such as changing the
turning it to the right (Figure 5-14, (4)) until it fuel filter) place an approved container under
contacts the mounting surface. Tighten one the opening to catch the fuel.
additional turn. NEVER use a shop rag to catch the fuel. Vapors
from the rag are flammable and explosive.
18. Open all fuel cocks in the fuel line. Wipe up any spills immediately.
Wear eye protection. The fuel system is under
19. Reconnect the fuel filter sensor connector
pressure and fuel could spray out when you
(Figure 5-14, (1)).
remove any fuel system component.
20. Prime the fuel system. See Priming the Fuel Failure to comply will result in death or serious
System on page 15. injury.
Figure 5-15
SCALD HAZARD!
NEVER remove the radiator cap if the engine is CAUTION
hot. Steam and hot engine coolant will spurt out
and seriously burn you. Allow the engine to
cool down before you attempt to remove the
radiator cap.
Tighten the radiator cap securely after you
check the radiator. Steam can spurt out during
engine operation if the cap is loose. ALWAYS be environmentally responsible.
ALWAYS check the level of the engine coolant Follow the guidelines of the EPA or other
by observing the reserve tank. governmental agencies for the proper disposal
Failure to comply will result in death or serious of hazardous materials such as engine oil,
injury. diesel fuel and engine coolant. Consult the local
authorities or reclamation facility.
NEVER dispose of hazardous materials
irresponsibly by dumping them into a sewer, on
the ground, or into ground water or waterways.
WARNING Failure to follow these procedures may
seriously harm the environment.
Figure 5-17
Perform the following maintenance every 1500 Proper operation of the crankcase breather system
hours of operation. is required to maintain the emission requirements of
the engine. The EPA / ARB requires that the
Inspect, Clean and Test Fuel Injectors crankcase breather system is inspected every 1500
Inspect Crankcase Breather System hours.
Inspect, Clean and Test Fuel Injectors There are three different crankcase breather
systems used on the TNV engines. Only the non-
turbo TNV engines crankcase breather system
WARNING requires periodic maintenance.
CAUTION
WARNING WARNING
CAUTION
ENTANGLEMENT HAZARD!
Stop the engine before you begin to service it.
NEVER leave the key in the key switch when you
are servicing the engine. Someone may
accidentally start the engine and not realize you
are servicing it. This could result in a serious FLYING OBJECT HAZARD!
injury.
ALWAYS wear eye protection when servicing the
If you must service the engine while it is engine and when using compressed air or high-
operating, remove all jewelry, tie back long hair, pressure water. Dust, flying debris, compressed
and keep your hands, other body parts and air, pressurized water or steam may injure your
clothing away from moving/rotating parts. eyes.
Failure to comply could result in death or Failure to comply may result in minor or
serious injury.. moderate injury.
CAUTION
Be sure to secure the engine solidly to prevent
injury or damage to parts due to the engine
falling during work on the engine.
63 Section 3. Engine
CAUTION CAUTION
Only use the engine coolant specified. Other Remove or install the high-pressure fuel
engine coolants may affect warranty coverage, injection lines as an assembly whenever
cause an internal buildup of rust and scale possible. Disassembling the high-pressure fuel
and/or shorten engine life. injection lines from the retainers or bending any
Prevent dirt and debris from contaminating the of the fuel lines will make it difficult to reinstall
engine coolant. Carefully clean the radiator cap the fuel lines.
and the surrounding area before you remove the
cap.
NEVER mix different types of engine coolants.
This may adversely affect the properties of the
engine coolant. CAUTION
Do not loosen or remove the four bolts retaining
the fuel injection pump drive gear to the fuel
injection pump hub. Do not disassemble the fuel
injection pump drive gear from the hub. Correct
CAUTION fuel injection timing will be very difficult or
Identify all parts and their location using an impossible to achieve.
appropriate method. It is important that all parts
are returned to the same position during the
reassembly process.
CAUTION
Do not allow the honing tool to operate in one
position for any length of time. Damage to the
cylinder wall will occur. Keep the tool in
constant up-and-down motion.
Cylinder Head
4TNV98 Engine
Reference
Inspection Item Standard Limit Page
0.0020 in. 0.0059 in.
Combustion Surface Distortion (Flatness)
(0.05 mm) or less (0.15 mm) See Valve
Recession
0.0142 - 0.0220 in. 0.0315 in. on
Valve Recession 4TNV98 Intake (0.36 - 0.56 mm) (0.8 mm) Page 95
(4-Valve Head) Exhaust 0.0138 - 0.0217 in. 0.0315 in. and 98.
(0.35 - 0.55 mm) (0.8 mm)
4TNE98 Engine
4TNV98 Engine
4TNE98 Engine
See Push
Less than 0.0012 in.
Page Push Rod Bend Rod Bend
0.0012 in. (0.03 mm) (0.03 mm)
on page 93.
Valve Spring
Reference
Inspection Item Model Standard Limit
Page
1.5630 in. 1.5433 in.
4TNV98 (4-Valve Head)
(39.7 mm) (39.2 mm)
Free Length See
1.87 in. Inspection of
4TNE98 -
(47.5 mm) Valve
0.0551 in. Springs on
4TNV98 (4-Valve Head) - page 97 and
(1.4 mm)
Squareness 101.
0.05 in.
4TNE98 -
(1.2 mm)
Reference
Inspection Item Standard Limit
Page
1.9681 - 1.9707 in. 1.9736 in.
Bushing Inside Diameter
(49.990 - 50.055 mm) (50.130 mm)
1.9655 - 1.9665 in. 1.9642 in.
Gear End Camshaft Outside Diameter
(49.925 - 49.950 mm) (49.890 mm)
0.0016 - 0.0051 in. 0.0094 in.
Oil Clearance
(0.040 - 0.130 mm) (0.240 mm)
1.9685 - 1.9695 in. 1.9724 in.
Bushing Inside Diameter
(50.000 - 50.025 mm) (50.100 mm) See
1.9650 - 1.9659 in. 1.9636 in. Inspection of
Intermediate Camshaft Outside Diameter
(49.910 - 49.935 mm) (49.875 mm) Camshaft on
page 125.
0.0026 - 0.0045 in. 0.0089 in.
Oil Clearance
(0.065 - 0.115 mm) (0.225 mm)
1.9685 - 1.9695 in. 1.9724 in.
Bushing Inside Diameter
(50.000 - 50.025 mm) (50.100 mm)
1.9655 - 1.9665 in. 1.9642 in.
Flywheel End Camshaft Outside Diameter
(49.925 - 49.950 mm) (49.890 mm)
0.0020 - 0.0039 in. 0.0083 in.
Oil Clearance
(0.050 - 0.100 mm) (0.210 mm)
Reference
Inspection Item Standard Limit
Page
1.8091 - 1.8100 in. 1.8071 in.
Shaft Outside Diameter See
(45.950 - 45.975 mm) (45.900 mm)
Inspection of
1.8110 - 4.8120 in. 1.8140 in.
Bushing Inside Diameter Idler Gear
(46.000 - 46.025 mm) (46.075 mm)
and Shaft on
0.0010 - 0.0030 in. 0.0069 in. page 126.
Oil Clearance
(0.025 - 0.075 mm) (0.175 mm)
Reference
Inspection Item Standard Limit
Page
Crank Gear, Cam Gear, Idler Gear, Fuel Injection 0.0031 - 0.0055 in. 0.0063 in. See
Pump Gear and PTO Gear (0.08 - 0.14 mm) (0.16 mm) Checking
Timing Gear
0.0035 - 0.0059 in. 0.0067 in. Backlash on
Lubricating Oil Pump Gear page 112.
(0.09 - 0.15 mm) (0.17 mm)
Reference
Inspection Item Standard Limit
Page
0.0008 in.
Bend (1/2 the dial gauge reading) -
(0.02 mm)
Journal Outside 2.2816 - 2.2820 in. 2.2796 in.
Diameter (57.952 - 57.962 mm) (57.902 mm) See
Inspection of
Bearing Inside 2.2835 - 2.2845 in.
- Crankshaft
Diameter (58.000 - 58.026 mm)
Connecting Rod Journals on Page
Bearing Insert 0.0587 - 0.0591 in. 124.
-
Thickness (1.492 - 1.500 mm)
0.0015 - 0.0029 in. 0.0059 in.
Oil Clearance
(0.038 - 0.074 mm) (0.150 mm)
Journal Outside 2.5572 - 2.5576 in. 2.5552 in.
Diameter (64.952 - 64.962 mm) (64.902 mm)
Bearing Inside 2.5590 - 2.5598 in. See
- Inspection of
Diameter (65.000 - 65.020 mm)
Main Bearing Journal Crankshaft
Bearing Insert 0.0785 - 0.0791 in. on page
-
Thickness (1.995 - 2.010 mm) 124.
0.0015 - 0.0027 in. 0.0059 in.
Oil Clearance
(0.038 - 0.068 mm) (0.150 mm)
Thrust Bearing
Reference
Inspection Item Standard Limit
Page
0.0051 - 0.0091 in. 0.0110 in. See
4TNV98 Removal of
(0.13 - 0.23 mm) (0.28 mm)
Crankshaft End Play Crankshaft
0.0043 - 0.0083 in. 0.0110 in. on Page
4TNE98
(0.11 - 0.21 mm) (0.28 mm) 118.
Reference
Inspection Item Standard Limit
Page
See
Piston Outside Diameter 3.8555 - 3.8567 in. 3.8541 in. Inspection of
(Measure at 90 to the Piston Pin.) (97.930 - 97.960 mm) (97.895 mm) Pistons,
Piston Rings
Piston Diameter Measure Location(Upward 0.8661 in. and Wrist
- Pin on page
From the Bottom of the Piston.) (22 mm)
122.
1.1811 - 1.1815 in. 1.1826 in. See
Hole Inside Diameter Inspection of
(30.000 - 30.009 mm) (30.039 mm)
Pistons,
1.1807 - 1.1811 in. 1.1795 in.
Piston Pin Pin Outside Diameter Piston Rings
(29.989 - 30.000 mm) (29.959 mm)
and Wrist
0.0000 - 0.0008 in. 0.0031 in. Pin on page
Oil Clearance
(0.000 - 0.020 mm) (0.080 mm) 122.
Piston Ring
Reference
Model Inspection Item Standard Limit
Page
0.0803 - 0.0811 in.
Ring Groove Width -
(2.040 - 2.060 mm)
0.0764 - 0.0772 in. 0.0756 in.
Ring Width
(1.940 - 1.960 mm) (1.920 mm)
Top Ring
0.0031 - 0.0047 in.
Side Clearance -
(0.080 - 0.120 mm)
0.0098 - 0.0177 in. 0.0213 in.
End Gap
(0.250 - 0.450 mm) (0.540 mm)
0.0819 - 0.0825 in. 0.0864 in.
Ring Groove Width
(2.080 - 2.095 mm) (2.195 mm) See
0.0776 - 0.0783 in. 0.0768 in. Inspection of
Ring Width Pistons,
(1.970 - 1.990 mm) (1.950 mm)
4TNV98 Second Ring Piston Rings
0.0035 - 0.0049 in. 0.0096 in. and Wrist
Side Clearance
(0.090 - 0.125 mm) (0.245 mm) Pin on page
0.0177 - 0.0256 in. 0.0287 in. 122.
End Gap
(0.450 - 0.650 mm) (0.730 mm)
0.1187 - 0.1193 in. 0.1232 in.
Ring Groove Width
(3.015 - 3.030 mm) (3.130 mm)
0.1169 - 0.1177 in. 0.1161 in.
Ring Width
(2.970 - 2.990 mm) (2.950 mm)
Oil Ring
0.0010 - 0.0024 in. 0.0071 in.
Side Clearance
(0.025 - 0.060 mm) (0.180 mm)
0.0098 - 0.0177 in. 0.0217 in.
End Gap
(0.250 - 0.450 mm) (0.550 mm)
Reference
Inspection Item Standard Limit
Page
Tappet
Cylinder Block
Reference
Inspection Item Standard Limit
Page
3.8583 - 3.8594 in. 3.8634 in. See
Cylinder Inside Diameter
(98.000 - 98.030 mm) (98.130 mm) Inspection
Roundness of Cylinder
0.0004 in. (0.01 mm) 0.0012 in. Block on
Cylinder Bore
Taper or less (0.03 mm) page 121.
Lubricating Oil
Thread Diameter Application
Component Torque
and Pitch (Thread Portion
and Seat Surface)
76 - 83 ftlb
Cylinder Head Bolt M11 x 1.25 mm (103.1 - 112.9 Nm; Applied
10.5 - 11.5 kgfm)
40 - 43 ftlb
Connecting Rod Bolt M10 x 1.0 mm (53.9 - 58.8 Nm; Applied
5.5 - 6.0 kgfm)
137 - 152 ftlb
Flywheel Bolt M14 x 1.5 mm (186.2 - 205.8 Nm; Applied
19 - 21 kgfm)
Lubricating Oil
Thread Diameter and Application
Component Torque
Pitch (Thread Portion
and Seat Surface)
80 - 87 ftlb
Main Bearing Cap Bolt M11 x 1.25 mm (108.1 - 117.9 Nm; Applied
11.0 - 12.0 kgfm)
80 - 94 ftlb
Crankshaft Pulley Bolt M14 x 1.5 mm (107.9 - 127.5 Nm; Applied
11.0 - 13.0 kgfm)
17 - 21 ftlb
Fuel Injector
4TNV98 M8 x 1.25 mm (22.6 - 28.4 Nm; Not Applied
Bolt
2.3 - 2.9 kgfm)
Fuel Pump 83 - 90 ftlb
Drive Gear 4TNV98 M18 x 1.5 mm (113 - 123 Nm; Not Applied
Nut 11.5 - 12.5 kgfm)
174 - 217 inlb
High-Pressure
4TNV98 M12 x 1.5 mm (19.6 - 24.5 Nm; Not Applied
Fuel Lines Bolt
2.0 - 2.5 kgfm)
70 - 86 inlb
Fuel Return
4TNV98 M6 x 1.0 mm (7.8 - 9.8 Nm; Not Applied
Line Joint Bolt
0.8 - 1.0 kgfm)
See Tightening Torques for Standard Bolts and Nuts on page 23 for standard hardware torque values.
Model L1 L2 d1 d2
Valve Guide 0.787 in. 2.953 in. 0.256 in. 0.394 in.
Tool (For 4TNV98
1 (20 mm) (75 mm) (6.5 mm) (10 mm)
Removing
Valve Guide) 0.787 in. 2.953 in. 0.295 in. 0.433 in.
4TNE98
(20 mm) (75 mm) (7.5 mm) (11 mm)
Locally Manufactured
Model L1 L2 d1 d2
Valve Guide 0.276 in. 2.362 in. 0.512 in. 0.630 in.
Tool (For 4TNV98
2 (7 mm) (60 mm) (13 mm) (16 mm)
Installing
Valve Guide) 0.591 in. 2.559 in. 0.551 in. 0.787 in.
4TNE98
(15 mm) (65 mm) (14 mm) (20 mm)
Locally Manufactured
Connecting
Rod Bushing L1 L2 d1 d2
Replacer
(For 0.787 in. 3.937 in. 1.181 in. 1.299 in.
4 Removal/ (20 mm) (100 mm) (30 mm) (33 mm)
Installation of
Connecting
Rod Locally Manufactured
Bushing)
Valve Spring
Compressor
(For Yanmar Part No.
5
Removal/ 129100-92630
Installation of
Valve Spring)
Model d1 d2 d3 L1 L2 L3
Locally Manufactured
L1 L2 d1 d2
Camshaft
Bushing Tool 0.709 in. 2.756 in. 1.968 in. 2.087 in.
(For (18 mm) (70 mm) (50 mm) (553 mm)
8
Extracting
Camshaft Allowance :
- 0.3
d1 - 0.6 , d2
- 0.3
- 0.6
Bushing)
Locally Manufactured
Piston Ring
Yanmar Part No. 95550-002476
Compressor
10 The Piston Insertion Tool is Applicable for 2.362 - 4.921 in.
(For Installing
(60 - 125 mm) Diameter Pistons
Piston)
Piston Ring
Expander
(For Removal
11 Available Locally
/ Installation
of Piston
Ring)
Crankshaft
12 Pulley Locally Manufactured
Installing Tool
1 Dial Indicator Locally Available Measure shaft bend and end play
Depth
7 Locally Available For measuring of valve recession
Micrometer
16
4TNV98 Engine
Figure 6-36
2. Remove the high pressure fuel injection lines 6. Disconnect the electrical wire from the intake air
(Figure 6-37, (1)). See Removal of Fuel Injectors heater (Figure 6-38, (12)).
on page7-31.
7. Remove the intake manifold bolts (Figure 6-38,
(11)). Remove the intake manifold (Figure 6-38,
(10)). Discard the intake manifold gasket (Figure
6-38, (9)).
Figure 6-37
Figure 6-39
1. Remove the fuel injectors from the cylinder head. NOTE : Identify the rocker arms so they can be
See Removal of Fuel Injectors on page 163. reinstalled with the original matching valve and
pushrod.
2. Remove the bolts (Figure 6-41, (1)) that retain the
rocker arm shaft supports to the cylinder head. 1. Remove the rocker arm shaft alignment studs
(Figure 6-42, (5)) from the rocker arm shaft
3. Remove the rocker arm and shaft assembly from supports (Figure 6-42, (6)).
the cylinder head.
2. Slide the supports, wave washers (Figure 6-42,
NOTE : Identify the push rods and valve bridges so (7)), rocker arms (Figure 6-42, (8)), and fuel
they can be installed in their original locations. injector retainers (Figure 6-42, (4)) off the rocker
shaft (Figure 6-42, (1)), leaving these parts in
4. Remove the push rods (Figure 6-41, (2)). order on the bench surface.
Figure 6-42
Figure 6-41
Figure 6-43
1) Cooling Fan End
2) Camshaft Side
Figure 6-44
2. Remove the cylinder head bolts (Figure 6-44, (1)).
3. Lift the cylinder head away from the cylinder block. Removal of Intake and Exhaust Valves
Discard the cylinder head gasket (Figure 6-44,
(2)). Place the cylinder head on the work bench to 1. Place the cylinder head on the work bench with
prevent damage to the combustion surface. the combustion side down.
Figure 6-45
4. Slowly release the tension on the valve spring. NOTE : Removal of the valve guides should be
postponed until inspection and measurement
5. Remove the spring retainer (Figure 6-46, (2)), procedures have been performed. See Inspection of
valve spring (Figure 6-46, (3)). Valve Guides on page 94.
Figure 6-47
Figure 6-46
Figure 6-1
Prepare a clean, flat working surface on a 1. Remove the glow plug cover (Figure 6-3, (2))
workbench large enough to accommodate the from each of the glow plugs (Figure 6-3, (1)).
cylinder head assembly. Discard all gaskets, O-rings
and seals. 2. Disconnect the glow plug harness (Figure 6-3,
(3)) from the glow plugs.
Figure 6-3
1. Remove the bolt (Figure 6-6, (1)) and locking 1. Remove the rocker arm shaft alignment screw
nuts (Figure 6-6, (2)) that retain the rocker arm (Figure 6-7, (1)) from the support bracket that
support brackets to the cylinder head. secures the rocker arm shaft (Figure 6-7, (2)).
2. Lift the rocker arm assembly from the cylinder 2. Remove the retaining rings (Figure 6-7, (3)) from
head. the ends of the rocker arm shaft (Figure 6-7, (2)).
3. Lift the push rods from the cylinder head. 3. Slide the rocker arm shaft (Figure 6-7, (2)) out of
the rocker arm support brackets (Figure 6-7, (4)),
4. Number the push rods so that they are reinstalled springs (Figure 6-7, (5)), and rocker arms (Figure
with the same valve tappet and rocker arm. -7, (6)).
Figure 6-8
Figure 6-10
Figure 6-12
WARNING
Figure 6-11
CAUTION
Any part which is found defective as a result of
inspection or any part whose measured value
does not satisfy the standard or limit must be
replaced.
CAUTION
Any part determined to not meet the service
standard or limit before the next service, as
determined from the state of current rate of wear, Figure 6-48
should be replaced even though the part
currently meets the service standard limit.
Inspection of Rocker Arm Assembly
Figure 6-51
Figure 6-50
Figure 6-52
Figure 6-54
Valve Recession
Figure 6-55
Figure 6-56
Figure 6-58
Use a flat surface and a square to check each Measure the diameter of the valve bridge guide pin
spring for squareness (Figure 6-59). See Valve bore in the valve bridge and guide pin (Figure 6-61,
Spring on page 68 for the service limit. (3)). See Rocker Arm and Shaft on page 68 for the
service limit.
Figure 6-59
Figure 6-61
IMPORTANT
Liberally oil all components during reassembly to
prevent premature wear or damage.
IMPORTANT
4TNV98 Engine Always install new valve stem seals. The exhaust
valve seals can be identified by having yellow paint.
Ensure they are installed in the correct locations.
1. Oil the lip of the valve stem seal (Figure 6-64, (2)).
Using the valve stem seal installation tool (Figure
6-64, (1)), install a new valve stem seal on each of
the valve guides (Figure 6-64, (3)).
4TNE98 Engine
Figure 6-65
4TNV98 Engine
Figure 6-67
Figure 6-68
1) Fan End
2) Camshaft Side
4TNV98 Engine
Figure 6-70
1. Reinstall the valve bridges (Figure 6-69, (3)) in
their original locations and ensure each seat
(Figure 6-69, (4)) is in place.
IMPORTANT
Ensure the lubrication holes (Figure 6-71, (1)) in the
2. Insert the push rods (Figure 6-69, (2)) in their
rocker arm shaft are oriented correctly with respect
original locations.
to the rocker arms (Figure 6-71, (2)).
Figure 6-71
Figure 6-72
7. Align the push rods with their respective rocker 2. Position the rocker arm assembly on a flat surface.
arms. Install the retaining rings (Figure 6-31, (3)) onto
the end of the rocker arm shaft.
8. Reinstall and tighten the rocker arm shaft
retaining bolts to the specified torque. 3. Install and hand tighten the rocker arm shaft
retaining bolt and nuts.
9. Tighten the rocker arm shaft alignment studs.
4. Install the valve adjusting screws (Figure 6-31,
10. Adjust the valve clearance. (7)) and lock nuts (Figure 6-31, (8)).
11. Reinstall the fuel injectors. See Installation of the 5. Place the rocker arm assembly in place onto the
Fuel Injectors on page 167. cylinder head. Tighten the rocker arm support
bracket nuts and bolt to the specified torque.
Tighten the rocker arm shaft alignment screw.
2. Place the valve cover on the cylinder head. 11. Reinstall the alternator.
3. Be sure new O-rings (Figure 6-73, (5)) are 12. Reconnect the turbocharger oil supply and drain
installed on the valve cover nuts. Reinstall and lines.
tighten the valve cover nuts (Figure 6-73, (4)).
13. Reconnect the air intake hose.
Figure 6-73
7. Reconnect the fuel injector return hose and fuel Figure 6-33
injection pump coolant hoses.
4-Cylinder Engines
Cylinder No. 1 2 3 4
1. Remove the valve cover. See Removal of Valve 5. To assure the valve bridge contacts the rear valve,
Cover on page 103. apply light, downward (Figure 6-79, (4)) finger
pressure on the valve bridge (Figure 6-79, (3),
NOTE : If adjusting each cylinder individually, the and loosen the valve bridge adjusting screw
cylinder to be adjusted first does not have to be the (Figure 6-79, (1)), until there is visible clearance
No. 1 cylinder. Select and adjust the cylinder where (Figure 6-81, (2)) between the adjusting screw
the piston is nearest to the top dead center after and the front valve.
turning, and make adjustment for other cylinders in
the order of firing by turning the crankshaft 180 6. To assure the valve bridge has equal contact with
each time. the front and rear valves, apply light downward
(Figure6-79,(4)) pressure on the valve bridge
2. Rotate the crankshaft clockwise as seen from the (Figure6-79,(3)), adjust the valve bridge adjusting
coolant pump end, to bring No. 1 piston to TDC on screw (Figure 6-79,(1)), (Figure 6-81,(1)) so
the compression stroke while watching the rocker there is zero 0clearance (Figure 6-81,(2))
arm motion and the timing grid on the flywheel. between the adjusting screw and the front valve.
(Position where both the intake and exhaust
valves are closed.)
Figure 6-79
Figure 6-80
Figure 6-82
Figure 6-84
Prepare a clean, flat working surface on a 9. Remove the fuel injection pump from the gear
workbench large enough to accommodate the case / front plate only if it must be sent out for
engine components. Discard all used gaskets, O- repair, or will interfere with other procedures such
rings and seals. Use new gaskets, O-rings and seals as hot tank cleaning. If the fuel injection pump
on reassembly of engine. does not need to be repaired, leaving it mounted
to the timing gear case or plate will eliminate the
need to re-time it during reassembly. See Fuel
Injection Pump on page 141.
CAUTION
10. Remove the starter motor. See Removal of
Identify all parts and their location using an
Starter Motor on page 225.
appropriate method. It is important that all parts
are returned to the same position during the
reassembly process.
Disassembly of Camshaft and Timing
Components
If the engine will be completely disassembled, the Discard all gaskets, O-rings and seals. Use new
following preliminary steps should be performed: gaskets, O-rings and seals on reassembly of the
camshaft and timing components.
1. Disconnect the battery cables at the battery.
Always disconnect the negative (-) cable first. Removal of Timing Gear Case Cover
2. Remove the throttle cable, electrical connections, 1. Remove the bolt and washer retaining the
intake and exhaust system connections, and fuel crankshaft pulley.
supply lines from the engine.
5. Remove the engine from the machine. Mount the 2. Remove the crankshaft pulley using a gear puller.
engine to a suitable engine repair stand having
adequate weight capacity. 3. Remove the bolts that retain the gear case cover
to the cylinder block and oil pan.
CAUTION
4. Remove the gear case cover (Figure 6-85, (1)).
Be sure to secure the engine solidly to prevent
injury or damage to parts due to the engine
falling during work on the engine.
Figure 6-87
4TNV98 Engine
Figure 6-88
Figure 6-90
Figure 6-92
Figure 6-91
Figure 6-93
3. Rotate the engine in the engine stand so that 4. Inspect and measure the camshaft bushing.
gravity causes the tappets (Figure 6-94, (5)) to See Camshaft on page 68 for the service limit. If
drop away from the camshaft lobes. damaged or worn beyond service limits, remove
the camshaft bushing (Figure 6-95, (3)).
NOTE : Rotate the camshaft at least two turns to
bump any sticking tappets away from the camshaft. 5. Remove two O-rings (Figure 6-95, (2)).
CAUTION
Keep the piston pin parts, piston assemblies,
and connecting rod assemblies together to be
returned to the same position during the
reassembly process. Label the parts using an
appropriate method.
IMPORTANT
NOTE : Pistons can fall from cylinder block if the 2. Measure bearing oil clearance prior to removing
engine is inverted. Rotate the engine so the the pistons and connecting rods to determine
connecting rods are horizontal before removing the extent of wear. Record the measurements.
connecting rod caps.
IMPORTANT
Do not rotate the crankshaft when using 6. Remove the compression rings (Figure 6-100,
PLASTIGAGE. A false reading may result. (3)) from the piston using a piston ring expander.
Figure 6-100
Figure 6-102
Figure 6-103
Figure 6-104
Figure 6-105
IMPORTANT
Figure 6-107
(c) Reinstall bearing caps and tighten to
specification. See Special Torque Chart on page
69. Inspection of Crankshaft and Camshaft
Components
(d) Remove bearing caps.
6. Remove the crankshaft from the engine. Replacement of Crankshaft Oil Seals
7. Remove the bearing inserts (Figure 6-104, (1)) 1. Remove the seal (Figure 6-108, (2)) from the
and thrust bearings (Figure 6-104, (2)). cover (Figure 6-108, (1)).
Figure 6-110
Figure 6-109
Figure 6-113
Figure 6-111
Figure 6-114
Figure 6-118
Inspection of Crankshaft
2. Place the connecting rod bearing inserts into the 2. Place a dial indicator (Figure 6-119, (3)) on a
connecting rod and connecting rod cap. Install the center main bearing surface.
rod cap and tighten the bolts to the specified
torque.
Inspection of Tappets
Figure 6-119
Figure 6-121
Figure 6-120
Figure 6-122
1. Measure the I.D. of the front bushing and the A bored cylinder should always be finished with a
remaining bores in the cylinder block. See hone to properly prepare the cylinder surface so
Camshaft on page 68 for specifications. the new piston rings will seat properly.
2. If the camshaft bushing is not within specification, After the cylinder has been bored and honed,
replace it using the appropriate service tool. If the install the appropriate oversize pistons and
remaining bores are not within specification, the piston rings.
cylinder block will require replacement as there
are no bearing inserts used. 2. Honing - Minor cylinder imperfections may be
corrected by using a rigid cylinder hone (Figure 6-
Inspection of Idler Gear and Shaft 126, (1)). Be sure not to exceed the maximum
cylinder bore specification.
1. Measure the outside diameter (Figure 6-124, (1)) Deglazing - A used cylinder that did not require
of the idler gear shaft (Figure 6-124, (2)). See boring or honing, should always be deglazed with
Idler Gear Shaft and Bushing on page 69 for a ball hone (Figure 6-126, (2)) before installing
specifications. new piston rings. This will properly prepare the
cylinder surface to allow new piston rings to seat
2. Measure the inside diameter (Figure 6-124, (3)) properly.
of the idler gear bushing (Figure 6-124, (4)). See
Idler Gear Shaft and Bushing on page 69 for NOTE : When honing a cylinder, with either a ridged
specifications. hone or a ball hone (Figure 6-125, (1)), move the
rotating hone up and down in the cylinder bore to
accomplish a 30 to 40 crosshatch pattern (Figure
6-125). This will provide the ideal surface for the
proper seating of new piston rings.
Figure 6-124
NOTES
Use a 50:50 mixture of diesel fuel and engine oil as All fasteners should be tightened to a given
a honing fluid. torque. If a special torque is not provided in the
Special Torque Chart on page 73, tighten to
Use a 300-grit hone at 300 - 1200 rpm standard torque specifications. See Tightening
(Figure 6-126). Torques for Standard Bolts and Nuts on page 4-
33.
Reassembly of Pistons
4TNV98 Engine
Figure 6-127
IMPORTANT
Figure 6-131
Figure 6-132
Figure 6-134
IMPORTANT
(1) Top Compression Ring End Gap.
(2) Second Compression Ring End Gap.
The oil ring expander (Figure 6-133, (4)) end gap
(3) Oil Ring End Gap.
must be located 180 from the oil ring (Figure 6-133,
(3)) end gap.
4TNE98 Engine
Figure 6-133
3. Install one circlip (Figure 6-70, (2)) into the piston. Install the top compression ring, second
compression ring and oil ring.
4. Position the connecting rod into the piston under
the skirt. The match marks on the connecting rod
must be opposite of the piston identification mark
(ID) on the top of the piston
Figure 6-73
Figure 6-71
IMPORTANT
Figure 6-74
4. Reinstall the main bearing caps (Figure 6-135,
Repeat these steps for the remaining pistons. (3)).
4TNV98 Engine
IMPORTANT
Figure 6-135
IMPORTANT
Figure 6-136
Orient the piston identification mark stamped on top 5. Apply a liberal coat of clean engine oil to the
of the piston on the fuel injection pump side of the bearing inserts and crankshaft journal.
engine
6. Apply a light coat of clean engine oil to the rod
cap bolts. Reinstall the connecting rod cap
When correctly assembled, the piston identification (Figure 6-140, (2)). Tighten the connecting rod
mark (Figure 6-138, (2)) stamped into the top of the bolts to the specified torque in two stages (1/2
piston will be on the same side of the connecting rod then full torque). See Special Torque Chart on
as the match marks (Figure 6-138, (4)) stamped page 69 for specifications.
into the connecting rod and connecting rod cap.
Figure 6-140
Figure 6-138
Figure 6-78
Figure 6-79
1. If removed, install a new camshaft bushing NOTE : If the engine is not installed on an engine
(Figure 6-141, (3)) using the appropriate service repair fixture, stand the engine upright on the
tool. flywheel end mounting flange.
2. Apply a continuous bead of Three Bond Liquid NOTE : The tappets are mushroom shaped and
Gasket No. 1212 to the mounting area of the gear must be installed from inside the engine crankcase.
case or front plate. Be sure to circle each bolt hole.
3. Lubricate the tappets with clean oil or assembly
3. Install two new O-rings (Figure 6-141, (2)) in the lube. Reinstall the tappets in their respective
cylinder block. locations in the cylinder block. Push the tappets
fully into the tappet bores so they will not interfere
with the installation of the camshaft.
Figure 6-141
Installation of Camshaft
Figure 6-143
NOTE : The gear housing or front plate must be
reinstalled prior to installing the camshaft. See 6. If removed, reinstall the fuel injection pump.
Installation of Gear Case or Front Plate on page 136. Adjust the fuel injection timing the engine after
installation. See Adjusting Fuel Injection Timing on
1. If removed, reinstall the camshaft end plate page 161.
(Figure 6-143, (1)), key, and timing gear (Figure
6-143, (4)) onto the camshaft using a press.
Installation of Timing Gears
NOTE : Heat the gear to 356 - 392F (180 - 200C)
and press onto the end of the camshaft. 1. Set the No. 1 piston to top dead center.
Figure 6-144
Figure 6-146
Figure 6-145
6. Ensure all three timing marks (Figure 6-144, (A, Figure 6-147
B, C)) are aligned.
4. Reinstall the washer and bolt. Tighten the bolt to
7. When all gears are properly aligned, tighten the the specified torque. See Special Torque Chart on
idler gear retaining bolts to specified torque. See page 73 for specifications.
Special Torque Chart on page 73 for specifications.
Figure 6-149
Figure 6-148
Final Reassembly of Engine
2. Apply a continuous bead of ThreeBond Liquid
Gasket No. 1212 to the mounting surface of the oil 1. Reinstall the starter motor.
pan (Figure 6-149, (1)). Be sure to circle each bolt
hole. 2. Reinstall the cylinder head. See Reassembly of
Cylinder Head on page 88 for the 4-valve cylinder
3. Reinstall the oil pan and tighten the bolts securely. head.
WARNING WARNING
WARNING
CAUTION
Never inject fuel toward you. Since the fuel is
injected at high pressure from the nozzle, it may
penetrate the skin, resulting in injury.
Never inject fuel toward a fire source. Atomized
fuel is highly flammable and may cause a fire or
burn skin.
PINCH HAZARD!
Carefully rotate the alternator toward the
cylinder block while loosening the V-belt.
Failure to comply may result in minor or
moderate injury.
CAUTION CAUTION
Do not rotate the crankshaft with the injection
Never use a steel wire brush to clean fuel
pump removed.
injectors. Damage to the nozzle and other
components is likely to result.
CAUTION
CAUTION Each pressure adjusting shim removed or
added changes the pressure threshold by
Allow the engine to warm-up for at least five
approximately 275 psi (1.9MPa, 19kgf/cm).
minutes and the idle speed of the engine to
Adding adjusting shims increases the threshold
return to normal before engaging the
pressure. Removing adjusting shims reduces
transmission or any PTOs. Engaging the
the pressure threshold.
transmission or PTO at an elevated engine
speed could result in an unexpected movement
of the equipment.
CAUTION
Remove or install the high-pressure fuel
injection lines as an assembly whenever
possible. Disassembling the high-pressure fuel
injection lines from the retainers or bending any
of the fuel lines will make it difficult to reinstall
the fuel lines.
Einführung
The MP fuel injection pumps are equipped with a The Yanmar TNV model engines are equipped with
stop solenoid that controls the fuel flow inside the a cold start device (CSD).
fuel injection pump.
The cold start device is located in the upper section
With the starter switch in the OFF position, no of the fuel injection pump and is connected to the
current flows to the stop solenoid and the solenoid engines cooling system.
plunger is extended holding the fuel injection pump
fuel rack in the closed position and not allowing The cold start device improves engine starting at
fuel to flow through the injection pump and to the lower temperatures. At engine cooling system
engine. temperatures below 41F (5C), the cold start
device advances the fuel injection timing and
When the starter switch is turned to the start slightly increases the fuel injection volume.
position, the pull coil (36.5 Amp draw/white wire)
inside the solenoid is activated and pulls the For approximately the first 5 minutes of operation,
solenoid plunger into the solenoid. This releases the idle speed of the engine will be slightly
the fuel injection pump fuel rack, allowing fuel to elevated.
flow through the injection pump and allowing the
engine to start and run.
CAUTION
When the starter switch is returned to the ON or Allow the engine to warm-up for at least five
RUN position, the pull coil no longer receives minutes and the idle speed of the engine to
current and the hold coil (0.5 Amp draw/red wire) return to normal before engaging the
inside the solenoid is activated. The hold coil transmission or any PTOs. Engaging the
holds the solenoid plunger in the RUN position, transmission or PTO at an elevated engine
allowing fuel to continue flowing and he engine to speed could result in an unexpected movement
continue running. of the equipment.
To stop the engine, the key switch is turned to the
OFF position. Current no longer flows to the stop
solenoid hold coil, and the solenoid plunger When the cold start device is activated, you may
extends and moves the injection pump fuel rack to notice a slight increase in the exhaust smoke of
the closed position, shutting off the fuel flow and the engine during engine warm-up.
stopping the engine.
Trochoid Fuel Pump
Failure of the stop solenoid could result in the
engine not starting, the engine stopping suddenly, NOTE: The trochoid fuel pump located on the side
the engine not continuing to run with the key switch of the MP fuel injection pump is not a fuel supply
returned to the ON or RUN position, or the engine pump. The function of this pump is to raise the
failing to stop when the key switch is turned to the pressure of the fuel supplied by the electric fuel
OFF position. Use a multimeter or continuity light to supply pump to the internal fuel pressure required
check for 12V at the stop solenoid connector in the by the MP fuel injection pump.
correct sequence.
The use of an electric fuel supply pump is required
on all TNV model engines with the MP fuel injection
pump.
Engine Injector
Model Fuel Injector Pressure Fuel Injection Timing
Class ID mark*
3133-3278 psi See Checking and Adjusting
4TNV98 VM V (21.6-22.6 MPa; Fuel Injection Timing on page
220-230 kgf/cm 157
NOTE: Fuel injection pressure of a new fuel injector is reduced approximately 72.5 psi (0.5 MPa; 5.0 kgf/cm)
after about 5 hours of operation due to the initial break in of the engine. When adjusting a new fuel injector or
after it has been disassembled for service, adjust the fuel injector 72.5 psi (0.5 MPa; 5.0 kgf/cm) higher than
the above standard.
NOTE: All fuel injectors have a three character identification mark (Figure7-2, (1)). The first character starts
with V or W.
Figure7-2
** Fuel injector identification is critical as each engine has a unique fuel injection pressure. The fuel nozzle is
specifically matched to the fuel injector by engine model and / or engine speed.
Measuring Instruments
No. Instrument Name Application Illustration
Mituotoyo 303613-
Extension Rod*
Locally Available
* These special service tools may also be available as an MP Fuel Injection Pump Special Tool Set, under a
different part number, in territories serviced by Yanmar America and Yanmar Europe. Contact your authorized
Yanmar dealer or distributor for details.
Figure7-3
(1) Diesel Fuel Tank. (2) Fuel Filter / Water Separator. (3) Electric Fuel Pump. (4) Fuel Filter. (5) Air Bleed Orifice. (6) Fuel Supply Line.
(7) Low Pressure Gallery. (8) Pressure Control Valve. (9) Trochoid Pump. (10) Oil Seal. (11) Fuel Injection Pump Cam.
(12) Engine Crankcase. (13) Tappet. (14) High Pressure Gallery. (15) Overflow Orifice. (16) Accumulator. (17) Timer Piston.
(18) Mono-Plunger. (19) Distributor Shaft. (20) Fuel Return Line. (21) High-Pressure Fuel Injection Lines. (22) Fuel Injector.
Figure 7-5
(1) High-Pressure Fuel Injection Lines. (2) Fuel Return Line. (3) Return Line-to-Cylinder Head Bolt (4) Fuel Injector.
(5) Injection Line Grommet. (6) Front Plate or Timing Gear Case. (7) Gear Case Cover. (8) Fuel Injection Pump Drive Gear Nut.
(9) Lock Washer. (10) Fuel Injection Pump Drive Gear Assembly (DO NOT remove or loosen the four bolts that fasten the injection pump
drive gear to the injection pump drive gear hub!). (11) Coolant Lines for Cold Start Device. (12) Fuel Injection Pump Insulator.
(13) Diesel Fuel Injection Pump. (14) Rear Fuel Injection Pump Support. (15) Fuel Filter / Water Separator.
(16) Electric Fuel Supply Pump. (17) Fuel Filter. (18) Fuel Filter Housing. (19) Stop Solenoid. (20) Cold Start Device (CSD).
(21) Trochoid Fuel Pump
Figure 7-6
NOTICE
To prevent rounding the fuel line nuts always use a
line or flare nut wrench. When loosening the fuel
line nuts, always hold the fuel injection pump delivery
valves with a back up wrench to prevent loosening of
the delivery valves.
Figure 7-7
6. First loosen the fuel line nuts at the fuel injectors
and then at the fuel injection pump. 10. Remove the fuel supply line (Figure 7-7, (4)).
Plug the open end of the line to minimize
leakage and prevent contamination.
Figure 7-9
Figure 7-8
IMPORTANT
Take care to not damage or bend the oil line. In
some applications, it may be preferable to
remove the complete oil line assembly from the
engine before proceeding.
Figure 7-10
Figure 7-13
Figure7-12
Figure 7-16
21. Once the fuel injection pump drive gear and hub
assembly has popped loose from the tapered
fuel injection pump drive shaft, carefully remove
the drive gear nut (Figure 7-15, (1)) and lock
washer (Figure 7-15, (2)).
Figure 7-17
Figure 7-15
IMPORTANT
Figure 7-18 If installing a new or recalibrated fuel injection
pump, locate and record the timing index
CAUTION number located on the pump housing boss on
the engine side of the new or recalibrated fuel
Do not rotate the crankshaft with the injection injection pump (Figure 7-19, (1)). This number
pump removed. will be used to calculate and adjust the final fuel
injection timing.
Figure 7-22
(1) Fuel Injection Pump Drive Gear. (2) Camshaft Drive Gear.
(3) Auxiliary Drive Gear (Optional). (4) Crankshaft Drive Gear.
(5) Direction of Rotation. (6) Oil Pump Drive Gear (4TNV94L -
4TNV106). (7) Idler Gear
Figure 7-19
1. Align the pump drive gear with the idler gear 3. Install a new O-ring on the pump mounting flange.
using the reference marks made earlier. Apply grease to the O-ring to hold it in place
4TNV98 model engines (Figure 7-21, (1)). during installation of the injection pump.
Figure 7-21
5. Reinstall the fuel injection pump drive gear lock Reinstall the timing grid sticker, provided with the
washer (Figure 7-23, (2)) and nut (Figure 7-23, new fuel injection pump, onto the back of the gear
(1)). Do not lubricate the threads of the nut or case / front plate (Figure 7-25). Align the
shaft. Hold the crankshaft pulley bolt with a standard mark (Figure 7-25, (1)) with the
socket wrench and tighten the drive gear nut to reference mark (Figure 7-25, (2)) made on the
the specified torque. See Special Torque Chart gear case during disassembly.
on page 143.
Figure 7-23
Figure 7-25
Figure 7-24
Figure 7-26
Timing Index Number In this case, rotate the top of the fuel injection
pump away from the cylinder block until the mark
Original injection pump= 6.8 on the outside upper mounting boss (Figure 7-28,
Replacement injection pump= 7.3 (1)) of the fuel injection pump aligns with the +0.5
mark on the timing sticker.
Difference= +0.5
Figure 7-30
Figure 7-31
Figure7-33
Figure 7-32
Figure7-35
Figure 7-37
Figure 7-38
Figure 7-42
11. Slowly rotate the crankshaft clockwise until the 1. Leave the dial indicator installed in the fuel
dial indicator shows a pump plunger lift of injection pump. Do not disturb the reading on the
2.5mm (0.098 in.). dial indicator.
12. Check the position of the flywheel target timing 2. Rotate the flywheel until the target timing mark
mark (previously determined) (Figure7-42, (1)) (Figure7-43, (1)) and the timing reference mark
in relation to the timing reference mark (Figure7-43, (2)) on the flywheel housing or
(Figure7-42, (2)) on the flywheel housing or back plate are aligned.
engine back plate. If the two marks are aligned,
the fuel injection timing is correct. If the marks
do not align, the fuel injection timing must be IMPORTANT
adjusted. See Adjusting Fuel Injection Timing
Do not rotate the crankshaft during the
on page 161.
remainder of this procedure.
13. If the injection timing is correct, remove the dial
indicator and adapter. Replace the pump
plunger plug and its copper gasket and tighten
to specifications. Replace the flywheel
inspection port cover. Open the fuel supply
valve and remove the clamp from the fuel
supply hose and the fuel return hose.
Figure 7-43
Figure 7-44
Figure 7-48
CAUTION CAUTION
Never use a steel wire brush to clean fuel
injectors. Damage to the nozzle and other
components is likely to result.
WARNING
Never inject fuel toward you. Since the fuel is
injected at high pressure from the nozzle, it may
penetrate the skin, resulting in injury.
Never inject fuel toward a fire source. Atomized
fuel is highly flammable and may cause a fire or Figure 7-49
burn skin.
4. Pump the operating lever of the tester slowly,
observing the pressure reading at the point
where the fuel injector begins spraying fuel
(Figure 7-49).
See Figure 7-52 for injector ID location.
Figure 7-50
Figure7-51
Figure 7-52
Figure 7-53
Figure 7-54
Each pressure adjusting shim removed or 1. Reinsert a new nozzle seat (Figure 7-57, (6))
added changes the pressure threshold by and nozzle protector (Figure 7-57, (5)) in the
approximately 275 psi (1.9 MPa, 19 kgf / cm). cylinder head for each injector.
Adding adjusting shims increases the threshold
pressure. Removing adjusting shims reduces 2. Reinstall a O-ring on to each injector body.
the pressure threshold.
3. Reinsert each fuel injector (Figure 7-57, (4)) into
the cylinder head.
1. Disassemble the fuel injector assembly. See 4. Reinstall the fuel injector retainers (Figure 7-57,
Disassembly and Inspection of Fuel Injectors on (3)) and torque the retaining bolts (Figure 7-57,
page 165. (2)) to specification.
2. Remove or add adjusting shims as needed. 5. Reinstall the fuel injector return line assembly
using new gaskets on each side of the injector
3. Reassemble the fuel injector assembly. See line screws.
Reassembly of Fuel Injectors on page 166.
6. Reinstall the fuel high-pressure fuel lines to each
4. Retest the fuel injector. See Testing of Fuel injector and tighten the nuts using a line or
Injectors on page 164. If the injector cannot be flare nut wrench.
adjusted to the appropriate pressure, discard the
fuel injector.
Figure 7-57
Measuring Instruments
Figure 7-1
Figure 7-2
Fuel is fed from the fuel tank into the fuel inlet of the Although the fuel pressure in the pump chamber is
injection pump by the feed pump built into the proportional to the pump revolution, excessive fuel
injection pump via the oil separator and fuel filter. is returned to the suction system by the regulating
valve when the pressure exceeds the specified
A filter is installed for fuel filtration. A filter with an oil value. The fuel is then sent to the plunger via the
separator for water separation is also provided at fuel path in the distributor head. The plunger
the bottom. applies high pressure to the fuel to feed it to the
nozzle and nozzle holder through the injection pipe.
Pressure is applied to feed fuel into the fuel inlet by
the feed pump in order to feed fuel into the injection The overflow valve above the injection pump
pump chamber. functions to maintain constant fuel temperature in
the pump chamber and return excessive fuel to the
fuel tank.
Figure 7-3
Pump
Figure 7-4
At the bottom of the injection pump is the built-in The feed pump functions to feed fuel from the fuel
timer. A timer spring having a set force is installed tank to the pump chamber.
on the low pressure side of the timer piston. The
fuel pressure in the pump chamber is directly The feed pump consists of the rotor, blade (vane)
applied to the other end (high pressure side) of the and liner. The rotor is driven by the drive shaft. The
timer piston. The position of the timer piston liner is located eccentrically to the center of the
changes according to the balance between the fuel rotor and four blades (vanes) are located between
pressure and the timer spring force to turn the roller the rotor and liner. When the rotor turns, the blades
holder via the roller holder pin. When the piston are pressed onto the liner inner wall by centrifugal
moves in the direction to compress the timer spring, force to change the capacity of the chambers
the roller holder moves in the advance direction according to the revolutions. When the capacity of a
(counter-revolution direction) to early the injection chamber increases, it draws fuel from the fuel tank.
timing. Thus, the timer controls the fuel injection
timing according to the fuel pressure in the pump When the capacity decreases, it feeds fuel into the
chamber. pump chamber.
Figure 7-8
Figure 7-9
Figure 7-3
Suction Process
Figure 7-12
Figure 7-10
Figure 7-13
Figure 7-11 The plunger begins rotating at the same time the
lifting process of the cam disc begins. When the
When the inlet port of the plunger barrel overlaps inlet port of the plunger barrel is covered by the
the inlet slit of the plunger during the lowering plunger, pressure feeding of fuel is initiated. At the
process of the plunger, the fuel in the pump same time, the highly pressurized fuel presses up
chamber is drawn into the plunger. the delivery valve when the outlet slit of the plunger
meets the outlet port of the plunger barrel. The fuel
is then injected into the engine combustion
chamber via the nozzle and nozzle holder.
When the plunger is further lifted up by the cam When the plunger turns a further 180 after the end
disc until the cutoff port of the plunger just overruns of fuel injection, the uniform pressure slit of the
the control sleeve, the high-pressure fuel in the plunger meets the outlet port of the plunger barrel.
plunger high-pressure chamber returns to the pump As a result, the pump chamber is connected to the
chamber through the cutoff port. As a result, the outlet port, thereby making the pressure in the
fuel pressure in the plunger becomes lower than chamber and outlet port equal. After the uniform
the set force of the delivery valve spring, so, the pressure process, the pressure in the outlet port
delivery valve closes to terminate pressure feeding becomes uniform, ensuring stable fuel injection.
of fuel.
The suction process through the uniform pressure
process are carried out for each cylinder during
every injection cycle.
While the plunger is rotating in the correct direction, The fuel injection volume is increased or decreased
the fuel is sufficiently drawn into the plunger since by changing the control sleeve position, resulting in
the inlet port of the plunger barrel opens during the change of the effective stroke. The effective stroke
plunger lowering process. The inlet port closes represents the plungers stroke from the time the
during the lifting process to inject the fuel. inlet port and inlet slit close until the cutoff port
overruns the control sleeve, which is proportional to
On the contrary, the inlet port of the plunger barrel the fuel injection volume. When the control sleeve
does not close during the plunger lifting process if moves to the left, the effective stroke (I2) decreases.
the engine rotates in the reverse direction. So, the When the control sleeve moves in the opposite
fuel is not pressurized, resulting in non-injection direction, or to the right, the effective stroke (I1)
state. increases to increase the fuel injection volume. The
control sleeve position is determined according to
the governor control.
Figure 7-21
If the remaining pressure is excessively high, cutoff NOTE: Cavitation represents the phenomenon
of the fuel may be adversely affected. where bubbles are generated in the pipe when the
pressure in the pipe drops. Cavitation erosion
The delivery valve also functions to improve fuel means erosion of the pipe inner wall as a result of
cutoff of the nozzle by drawing back the fuel in the cavitation.
pipe by the amount equal to the suck-back stroke of
the piston.
Figure 7-22
Figure 7-24
Figure 7-25
Figure 7-26
Figure 7-27
Figure 7-28
Figure 7-29
Figure 7-30
As shown in Figure7-30, the inside of the timer When pump revolutions increase and the pump
housing is separated into low and high pressure chamber pressure exceeds the set force of the
sides, the latter directly receiving the pump timer spring, the timer piston moves in the direction
chamber pressure. A timer spring having a set force to compress the spring ([B] in Figure7-30). This
is installed in the low pressure side. The timer turns the roller holder assembly in the reverse
piston slides horizontally based on the balance direction of pump revolution via the pin. This
between the spring force and changes in the pump causes the crest of the cam disc to quickly
chamber pressure. The movement of the timer approach the roller position of the roller holder, to
piston turns the roller holder assembly via the pin. advance the injection timing. On the contrary, when
pump revolutions decrease and the timer spring
force exceeds the pump chamber pressure, the
timer piston moves in the direction to delay the
timing.
Figure 7-31
Figure 7-32
Loosen the bolt (Figure7-34, (2)) that fastens NOTE: The cover is secured with an adhesive
the remaining bracket to the cylinder block and sealant. Use a gasket scraper to separate the cover
pivot down and away from the injection pump. from the gear case.
CAUTION
PINCH HAZARD!
Carefully rotate the alternator toward the
cylinder block while loosening the V-belt.
Failure to comply may result in minor or
moderate injury.
Also make matching marks (Figure7-38, (1)) on the 13. Using a two-bolt gear puller, remove the
rear of the gear case housing and on the fuel injection pump drive gear (Figure7-39, (3)) from
injection pump mounting flange before loosening the injection pump shaft.
the injection pump mounting nuts.
NOTE: The injection pump shaft is tapered with a
woodruff key. Once you have applied some
pressure with the puller. A slight hammer tap on
the center puller bolt will help pop the gear from
the shaft.
Figure 7-38
Figure 7-42
Figure 7-40 4. Thoroughly clean all old sealant from the fuel
injection pump cover (Figure7-43, (1)) and gear
2. Install the injection pump drive gear (Figure7-42, case housing. Apply ThreeBond, Yanmar Part No.
(3)) on the injection pump shaft lining up the two 977770-01212, or equivalent sealant to the fuel
marks you made on the pump drive gear with the injection pump cover. Install the fuel injection
mark you made on the idle gear. See (Figure7- pump cover on the front gear case with seven
37). bolts. Tighten the bolts to the specified torque.
Figure 7-41
Figure 7-46
Figure 7-48
Figure 7-49
Figure 7-50
CAUTION
When loosening or tightening the lines at the
fuel injectors, you must hold the fuel injector
with a second wrench to prevent the injector
from turning and damaging the fuel return line
Figure 7-51
fitting.
2. Unscrew the fuel injectors from the cylinder head.
Also remove the two copper washers and the
Then loosen the high pressure fuel line nuts nozzle protectors that will remain in the cylinder
(Figure7-50, (3)) on the fuel injection pump. head.
WARNING
Never inject fuel towards you. Since the fuel
in injected at high presure from the nozzle, it
may penetrate the skin, resulting in injury.
Never inject fuel towards a fire source. Figure 7-53
Atomized fuel is highly flammable and may
cause fire or skin burning. 6. Pump the operating lever more rapidly to
repeatedly pop the injector and observe the
spray pattern. See Judgement Criteria on
Atomization Conditionon page7-37 for examples
4. Pump the operating lever of the tester slowly, of good and bad spray patterns.
observing the pressure reading at the point
where the fuel injector begins spraying fuel. The 7. Finally. Pump the operating lever slowly to hold
fuel injectors for these engines should begin the pressure steady at a point just below the
spraying fuel at 1711 - 1914 PSI (11.8 - 13.2 pop off pressure point. Observe the injector to
MPa). The opening pressure may be adjusted by see that it is sealing properly and is not
adding or subtracting internal fuel injector shims. dripping.
Figure 7-52
A B C D E
Injection
Pattern
Pressure
Gauge Pointer fluctuate Same as A. Pointer stays at Although the Pressure does
Reading around the valve a position near pointer reaches not increase
opening the valve the valve even when the
pressure. opening opening tester lever is
pressure. pressure, the
pressure drop is
large.
1. Clean the exterior of the nozzle, taking care not Tighten the high pressure fuel line nuts
to damage the needle. (Figure7-55, (1)) on the fuel injectors.
5. Install the fuel return line fitting using new copper Figure 7-55
gaskets.
8. Prime the fuel system and check for leaks.
6. Tighten the fuel return line retaining nuts to
32.5ftlb (44.1Nm).
CAUTION
When loosening or tightening the lines at the
fuel injectors, you must hold the fuel injector
with a second wrench to prevent the injector
from turning and damaging the fuel return line
fitting.
DANGER WARNING
ENTANGLEMENT HAZARD!
SCALD HAZARD! Stop the engine before you begin to service it.
NEVER remove the radiator cap if the engine is NEVER leave the key in the key switch when
hot. Steam and hot engine coolant will spurt out you are servicing the engine. Someone may
and seriously burn you. Allow the engine to accidentally start the engine and not realize you
cool down before you attempt to remove the are servicing it. This could result in a serious
radiator cap. injury.
Tighten the radiator cap securely after you If you must service the engine while it is
check the radiator. Steam can spurt out during operating, remove all jewelry, tie back long hair,
engine operation if the cap is loose. and keep your hands, other body parts and
ALWAYS check the level of the engine coolant clothing away from moving/rotating parts.
by observing the reserve tank. Failure to comply could result in death or
Failure to comply will result in death or serious serious injury.
injury.
WARNING
WARNING
CAUTION CAUTION
If the engine coolant pump must be replaced,
replace the engine coolant pump as an
assembly only. Do not attempt to repair the
engine coolant pump or replace individual
components.
CAUTION
PINCH HAZARD!
Carefully rotate the alternator toward the
cylinder block while loosening the V-belt.
Failure to comply may result in minor or
moderate injury.
Figure 8-1
(1) Cylinder Head. (2) Thermostat. (3) Engine Coolant Pump. (4) Radiator. (5) Coolant Recovery Tank. (6) Engine Oil Cooler*
(7) Cylinder Block
Figure 8-2
(1) Thermostat Cover. (2) Thermostat Cover Gasket. (3) Thermostat. (4)Thermostat O-Ring. (5) Special O-Ring.
(6) Engine Coolant Pump. (7) Temperature Switch. (8) Gasket. (9) Engine Coolant Pump Gasket. (10) V-Belt.
(11) Engine Coolant Pump V-Pulley. (12) Spacer. (13) Engine Coolant Fan
Figure 8-3
Removal of Engine Coolant Pump 4. Drain the coolant from the engine block.
Verify the condition of the engine coolant pump On models equipped with an oil cooler, remove
before disassembling it from the engine. Check the the coolant hose (Figure 8-5, (1)) at the oil
engine coolant pump shaft bearing for abnormal cooler.
noise, sticking, excessive play and water leakage.
Replace the coolant pump if any of these conditions
are present.
CAUTION
If the engine coolant pump must be replaced,
replace the engine coolant pump as an
assembly only. Do not attempt to repair the
engine coolant pump or replace individual
components.
IMPORTANT
Figure 8-5
Make sure the engine and engine coolant are
not hot.
Figure 8-7
PINCH HAZARD!
Carefully rotate the alternator toward the
cylinder block while loosening the V-belt.
Failure to comply may result in minor or
moderate injury.
Figure 8-10
Figure 8-11
1. Reinstall the thermostat (Figure 8-12, (1)) and a 1. Position the engine coolant pump on the engine
new O-ring. and install a new gasket. Install a new special O-
ring (Figure 8-12, (5)) on assembly between the
engine coolant pump and the joint.
CAUTION
Use a new special O-ring between the engine
coolant pump and the joint. Be sure to use the
special O-ring for each engine model. Although
the O-ring dimensions are the same as a
commercially available O-ring, the material is
different.
Figure8-12
Figure 8-13
Figure 8-14
CAUTION
Only use the engine coolant specified. Other
engine coolants may affect warranty coverage,
cause an internal buildup of rust and scale
and/or shorten engine life.
Prevent dirt and debris from contaminating the
engine coolant. Carefully clean the radiator cap
and the surrounding area before you remove
the cap.
NEVER mix different types of engine coolants.
This may adversely affect the properties of the
engine coolant.
WARNING WARNING
ENTANGLEMENT HAZARD!
Stop the engine before you begin to service it. BURN HAZARD!
NEVER leave the key in the key switch when you Keep your hands and other body parts away
are servicing the engine. Someone may from hot engine surfaces such as the muffler,
accidentally start the engine and not realize you exhaust pipe, turbocharger (if equipped) and
are servicing it. This could result in a serious engine block during operation and shortly after
injury. you shut the engine down. These surfaces are
If you must service the engine while it is extremely hot while the engine is operating and
operating, remove all jewelry, tie back long hair, could seriously burn you.
and keep your hands, other body parts and Failure to comply could result in death or
clothing away from moving/rotating parts. serious injury.
Failure to comply could result in death or
serious injury..
WARNING
CAUTION CAUTION
If any oil pump component clearance exceeds its If the oil pump must be replaced, replace it as an
limit, the oil pump must be replaced as an assembly only. Do not replace individual
assembly. components.
42 - 57 psi
(0.29 - 0.39 MPa; All Models 8.8 psi (0.06 MPa 0.6 kfg/cm) or greater
3.0 - 4.0 kgf/cm)
Reference
Standard Limit
Page
Reference
Standard Limit
Page
Reference
Standard Limit
Page
0.0063 in.
Outer Rotor to Inner Rotor Tip Clearance on page 217
(0.16 mm)
Reference
Model Inspection Item Standard Limit
Page
0.5110 - 0.5126 in. 0.5138 in.
Gear Case Bearing I.D. Check Rotor
(12.980 - 13.020 mm) (13.05 mm)
Shaft
0.5100 - 0.5108 in. 0.5096 in.
4TNV98 Rotor Shaft O.D. Clearance
(12.955 - 12.975 mm) (12.945 mm)
on
0.0014 - 0.0026 in. 0.0041 in. page 216
Rotor Clearance
(0.035 - 0.065 mm) (0.105 mm)
0.5110 to 0.5126 in. 0.5138 in.
Gear Case Bearing I.D. Check Rotor
(12.980 - 13.020 mm) (13.05 mm)
Shaft
0.5089 to 0.5106 in. 0.5085 in.
4TNE98 Rotor Shaft O.D. Clearance
(12.925 - 12.970 mm) (12.915 mm)
on
0.0004 to 0.0026 in. 0.0041 in. page 216
Rotor Clearance
(0.010 to 0.065 mm) (0.105 mm)
Figure 9-1
Figure 9-14
CAUTION
If the oil pump must be replaced, replace it as an
assembly only. Do not replace individual
components.
CAUTION
If any oil pump component clearance exceeds its
limit, the oil pump must be replaced as an
assembly.
Figure 9-17
Determine the outer rotor to inner rotor tip clearance. Determine the rotor shaft clearance. Measure the
Insert a feeler gauge between the top of an inner outside diameter of the rotor shaft (Figure 9-20, (1))
rotor tooth (Figure 9-18, (1)) and the top of an outer and the bore diameter in the gear case housing
rotor tooth (Figure 9-18, (2)) and measure the (Figure 9-20, (2)).
clearance.
Calculate the difference between the two
measurements to determine the clearance.
Figure 9-18
Figure 9-20
Record the measurement(s) and see Outer Rotor to
Inner Rotor Tip Clearance on page 216 for the Record the measurement(s) and see Rotor Shaft
service limits. Clearance on page 215 for the service limits.
Figure 9-19
Figure 9-22
Figure 9-23
WARNING WARNING
ENTANGLEMENT HAZARD!
Stop the engine before you begin to service it. SHOCK HAZARD!
NEVER leave the key in the key switch when Always read and follow safety related
you are servicing the engine. Someone may precautions found on containers of hazardous
accidentally start the engine and not realize you substances like parts cleaners, primers,
are servicing it. This could result in a serious sealants and sealant removers.
injury. Failure to comply could result in death or
If you must service the engine while it is serious injury.
operating, remove all jewelry, tie back long hair,
and keep your hands, other body parts and
clothing away from moving/rotating parts.
Failure to comply could result in death or
serious injury. WARNING
CAUTION
The starter motor can be damaged if operated
continuously longer than 10 seconds while
performing the no-load test.
CAUTION
Make sure that the combined total resistance of
the battery cable in both directions between the
starter motor and the battery is within the value
indicated on the wiring diagram. The starter
motor will malfunction or break down if the
resistance is higher than the specified value.
No Load Loaded
DOOSAN Mfg.
Part Mfg. Part Specification Amp Amp
Terminal Terminal
Number Number erage rpm erage Torque rpm
Voltage Voltage
Draw Draw
97 in.-lb
DC12V-3.1 hp 140A 400
A408417 Hitachi S13-204 11 4100 7.7 (11.0 Nm; 1400
(2.3 kW) MAX Max
1.1 kgfm)
Figure 11-1
(1) Pinion Shaft. (2) M4 Bolts (3 used). (3) Bearing Retainer. (4) Pinion Clutch Assembly. (5) Return Spring. (6) Pinion Stop.
(7) Retaining Ring. (8) Gear Housing. (9) Shift Lever. (10) Torsion Spring. (11) Plunger. (12) Dust Covers (Shims).
(13) Magnetic Switch Assembly (Solenoid). (14) Cover. (15) M6 Bolts (2 used). (16) Armature Assembly. (17) Field Coil Assembly.
(18) Positive (+) Brushes. (19) Negative (-) Brushes. (20) Brush Holder Assembly. (21) Rear Cover. (22) M5 Through Bolts. (2 used).
(23) M4 Bolts (2 used)
WARNING
SHOCK HAZARD!
Turn off the battery switch (if equipped) or
disconnect the negative battery cable before
servicing the electrical system.
Check the electrical harnesses for cracks,
abrasions, and damaged or corroded
connectors. ALWAYS keep the connectors and
terminals clean.
Failure to comply could result in death or Figure 11-2
serious injury.
Figure 11-3
Figure 11-7
Figure 11-5
Figure 11-8
Figure 11-11
Armature
Figure 11-12
Figure 11-13
Figure 11-16
Measure the armature core run-out and the Check for continuity between the field coil terminal
commutator run-out using a dial indicator (Figure and the yoke using a multimeter (Figure11-19).
11-17). Replace the armature if either of the The multimeter should not indicate continuity.
measurements is less than the limit.
If the multimeter indicates continuity, replace the
field coil assembly.
Figure 11-17
Field Coil Continuity Test Measure the length of the brush (Figure11-20).
Replace the brush if the length is less than the limit.
Check for continuity between the field coil terminals
using a multimeter (Figure11-18). The multimeter
should indicate continuity.
Figure 11-20
Figure 11-18
If the starter motor becomes wet, replace the Check for continuity between the S and M
magnetic switch even if the magnetic switch terminals using a multimeter (Figure11-22). The
assembly function is normal. multimeter should indicate continuity.
Shunt Coil Continuity Test If the multimeter does not indicate continuity,
replace the magnetic switch.
Check for continuity between the S terminal and
the switch body using a multimeter (Figure11-21).
The multimeter should indicate continuity.
Figure 11-22
Figure 11-21
Figure 11-25
Figure 11-23 Rotate each ball bearing while holding the pinion
clutch assembly (Figure11-26). Replace the ball
bearing if it does not rotate smoothly or has
Pinion Clutch Assembly excessive play.
Figure 11-26
Figure 11-24
Figure 11-29
Figure 11-28
Figure 11-31
Figure 11-32
Figure 11-34
Figure 11-36
Compression Pressure
Engine Model at 250 rpm (250 min-1) Deviation Between
Cylinders
Standard Limit
483 - 513 psi 384 - 414 psi 29 - 43 psi
4TNV98
(3.33 - 3.53 MPa; (2.65 - 2.85 MPa; (0.2 - 0.3 MPa;
34 - 36 kgf/cm) 27 - 29 kgf/cm) 2 3 kgf/cm)
Figure 14-2
Figure 13-2
When the measured compression pressure is below the limit value, inspect each part by referring to the
table below.
4TNV98 Engine